HSEALERT

HSE ALERT
(Issued by HSE Department IMCC Abu Dhabi Group)

IMCC Ref: HSA-23 30.04.07

FAILED TACK WELD - FATAL CRUSH INJURY

What happened?

One of our fabricators was performing fit-up of a 14.6 m long hollow rectangular beam. The beam
was placed on four bottom support plates tack-welded to the main structure; two plates on each end.
While aligning the beam with a crow-bar, one of the support plates failed. Consequently the other
support plates yielded and the beam weighing approximately 2.5 ton fell from a height of 2 m,
fatally crushing the fabricator.

Another fabricator, on the other end of the beam, who was viewing the gap between the structure
and the beam from the side escaped unhurt. However, his hop-up scaffold which was beneath the
beam sustained damage.

Beam that fell

Incident spot Damaged scaffold

What went wrong?

• Failure of tack welds between the bottom support plate and the structure – there was not enough
weld cross-section volume, weld penetration and fusion – tack was done by an unqualified
fabricator!
• Failure to provide weld on either side of the support plates – use of 2 mm electrode and poor
surface preparation resulted in inadequate penetration and weld cross section (4-5 mm only).
• Use of crow-bar to push the beam imposed additional downward and horizontal stress on the
tack welded support plates - this enhanced the stress resulting weld failure.
• The activity was carried out while standing under the load.
 14.6 m, 2.5 ton beam

Support plates tack welded to the structure

Insufficient tack length & penetration

Poor surface preparation
What should we do to prevent recurrence?
• Only qualified tack welders to do tack welding – if you are not qualified do not do it!
• Overhead tack welding shall be done only by qualified welders.
• Supervision to ensure that welds are adequate for the tasks being undertaken.
• Position yourselves to avoid coming directly under any load which may fail – work from the
sides or from the top using a hop-up scaffold.
• Tack welding with 2 mm electrodes requires two passes & a minimum through 8 mm thickness
leg and shall be used only for light fabrication works. Heavy works greater than 1 ton require
SMAW tacking with a minimum of 3.25 mm electrode.
• Support plates are not to be used over and over again as it may affect integrity.
• Always ensure adequate and equal penetration on both sides of the joint – you may require
additional grinding to remove the tack, but it ensures safety.
• Ensure good and sufficient surface preparation prior to welding.
• Ensure welding slag is removed to enable the quality checking of the weld for defects.

‘REMEMBER BEHIND EVERY FATALITY IS A FAMILY IN PAIN’